Investigation of Chip Formation Characteristics during Surface Finishing of HDPE Samples

Authors: M. S. Kaiser, S. Reaz Ahmed

Abstract:

Chip formation characteristics are investigated during surface finishing of high density polyethylene (HDPE) samples using a shaper machine. Both the cutting speed and depth of cut are varied continually to enable observations under various machining conditions. The generated chips are analyzed in terms of their shape, size, and deformation. Their physical appearances are also observed using digital camera and optical microscope. The investigation shows that continuous chips are obtained for all the cutting conditions. It is observed that cutting speed is more influential than depth of cut to cause dimensional changes of chips. Chips curl radius is also found to increase gradually with the increase of cutting speed. The length of continuous chips remains always smaller than the job length, and the corresponding discrepancies are found to be more prominent at lower cutting speed. Microstructures of the chips reveal that cracks are formed at higher cutting speeds and depth of cuts, which is not that significant at low depth of cut.

Keywords: HDPE, surface-finishing, chip formation, deformation, roughness.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.3461990

References:

[1] P. Kovac, B. Savkovic, L. Siđanin, O. Lukac and I. Mankova, “The influence of material microstructure on the chip forming process,” Contemporary Materials, vol. 1, pp. 69-76, 2014.
[2] D. Chandramohan and B. Murali, “Machining of composites – a review,” Academic Journal of Manufacturing Engineering, vol. 12, no. 3, pp. 67-71, 2014.
[3] R.Teti, “Machining of Composite Materials,” CIRP Annals - Manufacturing Technology, vol. 51, no. 2, pp. 611-634, 2002.
[4] A. Mishra, “Overview study of the machining of composite materials,” International Journal of Research in Engineering and Technology, vol. 4, no. 7, pp. 1-8, 2016.
[5] I.S. Jawahir and C.A.van Luttervelt, “Recent Developments in Chip Control Research and Applications,” CIRP Annals - Manufacturing Technology, vol. 42, no. 2, pp. 659-693, 1993.
[6] M. Dogra, V.S. Sharmab and J. Durejac, “Effect of tool geometry variation on finish turning – A Review,” Journal of Engineering Science and Technology Review,vol. 4, no. 1, pp. 1-13, 2011.
[7] K.Q. Xiao and L.C. Zhang, “The role of viscous deformation in the machining of polymers,” International Journal of Mechanical Sciences, vol. 44, pp. 2317-2336, 2002.
[8] M. Gupta and . S. Kumar, “Investigation of surface roughness and MRR for turning of UD-GFRP using PCA and Taguchi method,” Engineering Science and Technology, vol. 18, no. 1, pp. 70-80, 2015.
[9] L.B. Abhang and M. Hameedullah, “Chip-tool interface temperature prediction model for turning process,” International Journal of Engineering Science and Technology, vol. 2, no. 4, pp. 382-393, 2010.
[10] S.A. Baeurle, A. Hotta and A.A. Gusev, “On the glassy state of multiphase and pure polymer materials,” Polymer, vol. 47, no. 17, pp. 6243-6253, 2006.
[11] V. Pednekar, V. Madhavan and A. H. Adibi-Sedeh, “Investigation of the transition from plane strain to plane stress in orthogonal metal cutting.,” In ASME 2004 International Mechanical Engineering Congress and Exposition, pp. 513-528, 2004.
[12] R. Liu, E. Eaton, M. Yu and J. Kuang, “An Investigation of Side Flow during Chip Formation in Orthogonal Cutting,” Procedia Manufacturing, vol. 10, pp. 568-577, 2017.
[13] I. Korkut, M. Kasap, I. Ciftci, and U. Seker, “Determination of optimum cutting parameters during machining of AISI 304 austenitic stainless steel,” Materials and Design, vol. 25, pp. 303-305, 2004.